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Title: CAD/CAM (CIM) Computer Aided Design/Computer Aided Manufacturing (Computer Integrated Manufacturing)


1
CAD/CAM (CIM)Computer Aided Design/Computer
Aided Manufacturing (Computer Integrated
Manufacturing)
Meung J. Kim, Ph.D, Professor Mechanical
Engineering Northern Illinois University DeKalb,
IL 60115 2013
2
Objectives
  • Introduction to CAD/CAM
  • Current Development Activities
  • References for Details

3
Contents
Part I. Introduction Part II. CAD Part III.
CAM Part IV. CAD/CAM Integration Part V. Current
Development
4
Part I INTRODUCTION
5
What is CAD/CAM (or CIM) Technology?
  • CAD makes representation of products and perform
    analysis of the design (about 70 of project)
  • CAM prepare manufacturing processes and drive
    machine tools (about 30 of project)
  • CIM CAM/CAM Other Activities Such As
    Operations Management and Master Storage and
    Handling.

6
History of CAD/CAM/CIM
7
Operational Flow of CIM
8
Manufacturing System Classification
The classification of the manufacturing system of
a company should identify the activities in the
three major process segments (ie, design,
manufacturing control and planning, and
production) in CIM wheel.
Business segment
Process segment
Infrastructure resources
9
Design Considerations
  • Part must function correctly and last reasonable
    duration of time
  • Functional considerations involve weight,
    strength, thermal properties, kinematics, and
    dynamics, etc.
  • Performance evaluation against design
    specifications
  • This is determined by a parts
  • geometry
  • material properties
  • environment
  • Part must be designed as closely as possible to
    the design specifications
  • The economic factors include
  • materials
  • processing costs
  • marketing details

10
Part II CAD
11
CAD TechnologiesEvolution
1950s SAGE System (Analyze Radar Image with
Light-pen) 1962 SketchPad at MIT (Interactive
Graphics with SketchPad) 1960s Digital Equipment
Corporation, Control Data, IBM, Univac, Applicon,
Calma, ComputerVision, Intergraph (Calma
Graphics System, ComputerVision, CADD System,
IBM CADAM, CATIA, Intergraph Graphics
System) 1970s Recognized as Indispensible Tools
to Improve Productivities especially in ME, EE,
and CE 1980s - 1990s Widely Spread Due To Lower
Price and availability of PC 1990s - Network
Based such as Internet, LAN, and WAN 2000s-
Cloud Computing
12
CAD Structure
  • Input Device
  • Output Device
  • CPU
  • Memory
  • Storage Device
  • Communication Device

13
Haptic I/O
Data Glove
14
CAD Technological Issues from Hardware
Perspective
Electronic Image -gt Visual Image (CRT, LCD, LED
with vector/raster painting)
Graphics Terminal Performance (Display Technology)
Storage of Display Image Format (Point-, Vector-,
Relationship-Oriented Storage)
Production of Display Image from Design
Computer Performance
  • Execution of Mathematical Functions Needed to
    Translate Stored Images into Display and to
    Manipulate Vector Representation Designs in
    Storage. Some Efforts are
  • Math-Coprocessor in PCs
  • Pre-Fetch Methods to reduce I-time in Intel
    8086-Family of Processors
  • RISC (Reduced Instruction Set Computer) to
    reduce I-time
  • Parallel Processors
  • Super Computers

Utilization of Existing Leading-Edge Technologies
like Artificial Intelligence (Pattern
Recognition, Planning, Voice Recognition, Robot
Control, Fault Diagnosis, and Expert Systems)
15
CAD Technological Issues from Software
Perspective
  • Multi-View 2D Modeler
  • 3D Wire Frame Modeler
  • 3D Surface Modeler
  • Solid Modeler -gt CAM

Geometric Modeling
  • Scaling
  • Rotation
  • Translation
  • Reflection
  • Visualization
  • Editing
  • Dimensioning and Labeling
  • Shading
  • Real-Time Animation

Rendering
Parametric and Variational Design
Feature-Based Design
  • Stress Analysis
  • CFD
  • Kinematics Analysis for Moving Parts
  • Simple Analysis like Area/Volume, Mass
    Calculations
  • Artificial Intelligence (AI) which works with
    facts and rules from which they can make
    deductions Pattern Recognition, Planning, Voice
    Recognition, Robot Control, Fault Diagnosis, and
    Expert Systems.

Analysis Help Engineers to Determine Feasibility
of Design FEM and other computational methods
Integrated Data Base Management and Optimization
  • CAD Drawing
  • Engineering Analysis
  • Modeling
  • NC
  • Robots
  • Process Planning
  • Management
  • IGES
  • ..

Virtual Reality (VR) Technology
16
CAD Data Exchangeability
  • Since the IGES was first developed under the
    guidance of National Bureau of Standards (NBS)
    87 in 1979, CAD/CAM data exchange had leaped
    beyond IGES. This brought about an effort from
    the international community to introduce a single
    international standard for graphics data
    exchange. As a result the Standard for the
    Exchange of Product Data Models (STEP, officially
    the ISO standard 10303) was introduced. The STEP
    is a series of International Standards with the
    goal of defining data across the full engineering
    and manufacturing life cycle to produce a single
    international standard for product data exchange.
    There are currently several standards like U.S.
    IGES, Frances SET, and Germanys VDA-FS.
  • The International Organization for
    Standardization (ISO) 88 is a worldwide
    federation of national standards bodies from some
    100 countries, one from each country and
    established in 1947. In USA an organization
    called The National Institute of Standards and
    Technology (NIST), formerly the National Bureau
    of Standards, was established by Congress in 1901
    to support industry, commerce, scientific
    institutions, and all branches of Government. For
    nearly 100 years the NIST/NBS laboratories have
    worked with industry and government to advance
    measurement science and develop standards.
  • There is another collaborative effort under the
    project INDEX (Intelligent Data Extraction) at
    Manchester Visualization Center of University of
    Manchester 63. This is also concerned with
    exchangeability of CAD/CAM data among different
    systems that provides a flexible software tool
    set.

17
Geometric Modeling Object Geometry
18
Principles of Orthographic Projection
19
Modeling Methodology
  • Boundary Representation (B-rep)
  • Constructive Solid Geometry (CSG)
  • Sweep Representation
  • Analytic Solid Modeling (ASM)
  • Pure Primitive Instancing (PPI)
  • Cell Decomposition
  • Spatial Enumeration
  • Octree Encoding

20
Modeling Techniques
  • Extrude
  • Revolve
  • Sweep
  • Blend

21
Analyses
  • Structural Analyses
  • Heat Transfer Analyses
  • Fluid Analyses
  • Coupled-Field Analyses
  • Linear and Nonlinear Analyses

22
Choosing a Solid Modeler forCAD/CAM Integration
  • Flexibility (must be able to handle all kinds of
    objects)
  • Robustness (should produce a consistent and
    proper solid)
  • Simplicity (must be simple and user friendly)
  • Performance (speed is important that should be
    improved with software methodology and
    hardware)
  • Economy (solid modeler is expensive, but will
    pay for itself as time goes on with CAD/CAM)

23
Part III CAM
24
Tool Path Geometry
The figure above shows some geometries to
consider for tool-path generation. There are
various approaches to determine the tool path.
For example, the surface normal and tangent
vectors at each point.
25
Milling Machines
26
CAM TechnologiesHistory
  • 1909 Automation by Ford Automobile Company
    (Mass Production)
  • 1923 Automatic Transfer Machines at Morris
    Engine Factory, England
  • 1952 Numerical Controls (NC) for tool
    positioning thru computer commands
  • 1959 Control Digital Computer at Texaco
    refinery, Texas
  • 1960 Robot Implementation - Unimate based on NC
    principles
  • 1965 Production-Line Computer Control (IBM
    developed plcc for circuit boards)
  • 1970 Direct Numerical Control (DNC) --gt
    Multiple-Machine Computer Control (Japanese
    National Railways several machine tools under
    simultaneous control of a computer)
  • 1970-1972 Computer Numerical Control (CNC)
    each machine tool has its own memory (PC)
  • 1975-1980 Distributed Numerical Control (DNC)
    a main computer downloads NC programs to
    applicable machine. This is the key concept to
    CAM advances.
  • 1980s Cellular Manufacturing A reduction of
    combinations in job shop control is achieved by
    identifying families of parts that can be
    produced on a subset of equipment in the job
    shop. This determination of families and
    equipment is most often done by group technology.
    Then the cell control computer download NC
    programs and effect material handling between
    machines, frequently thru robot transfers.
  • - Flexible Manufacturing Systems The
    idea of using a set of machines to produce a
    relatively wide variety of products, with
    automatic movement of products through any
    sequence of machines, including testing, is the
    heart of the flexible manufacturing systems.
  • 2000s 3D Printing

27
Manufacturing Cell
28
Computers in ManufacturingManufacturing Control
Computer Control (late 1950s)
Numerical Controls (NC)
Numerical control (NC) is a concept of machine
control that consists of several steps such as
development of manufacturing plan for a part,
programming numerical control instructions,
process the program to locate the tool path, and
post-process for a specific machine tool. NC
activities consist of NC machines like CNC and
DNC and processor language like APT in addition
to the human operator.
29
Robots in Manufacturing
  • Industrial robots have been used in the
    manufacturing more than two decades. It is no
    doubt that robots will play a crucial role in the
    future manufacturing. Though, there are still
    quite challenging technologies to overcome in
    this field of technology such as
  • vision system
  • position sensing
  • hand tactile sensing
  • dexterous linkage
  • control methodology.

30
Sensing/Measuring/Quality Controls
Sensing and measuring are also essential part of
manufacturing such as quality controls and had
been integrated into CAD/CAM.
31
CAM Technological Issues from Software
Perspective
  • Axiomatic Design
  • DFM
  • Design Science
  • DFA
  • Taguchi Method
  • MPDR, Group Technology
  • FMEA

Concurrent Engineering
  • Hierarchical Code
  • Attribute Code
  • Process Planning (CAPP)
  • Manual Approach
  • Variant Approach
  • Generative Approach

Group Technology
  • Production Control
  • Cellular Manufacturing
  • JIT Manufacturing

Manufacturing Planning and Control
  • Timing
  • Priority Interrupts
  • Real-Time, Multi-Tasking Operating Systems
  • Numerical Control (NC)
  • NC/CNC/DNC Machines
  • NC Programming APT,ADAPT,EXAPT,etc.

Computer Control and PLC
Robotics
Artificial Intelligence
  • Sensing
  • Measuring
  • Quality Control

Measurement and Verification
32
Artificial Intelligence (Expert Systems)
Probably the most prominent artificial
intelligence is the expert system, which mimic
the human intelligence through a stored
knowledge-based data.
Expert system uses the AI technology to formulate
facts and rules in a given field, based on
specialists knowledge of that field, make that
information available to designers.
As much as the concept of expert systems are so
attractive, it is far more expensive to develop,
store, and access a major subset of the entire
body of knowledge on a given topic than provide a
limited subset in a traditional form. This is one
of the major reasons that expert systems are
still not fully adopted in CAD/CAM. Another
reason is that expert systems are more difficult
to test because there is no limit to the number
of different requests which might make to users.
Despite of the difficulty in building and
validating expert systems and the resources
required to support their use, their high value
in CAD/CAM applications will drive their further
development to support design and use in the
future. Some of the current tasks performed by
humans will then be replaced by expert systems
such as design optimization and process planning.
Any major CAD/CAM vendors who are not actively
developing such products would risk their place
in the future market.
33
Part IV CAD/CAM Integration
34
Concurrent Engineering
CE is an approach to design and manufacturing
activities, which tries to complete the design in
parallel to process planning, field-support,
quality control, and other manufacturing-related
activities. Its mission is to design and optimize
the product under the constraints such as
functionality, producibility, and cost.
  • Axiomatic design
  • Design for manufacturing (DFM)
  • Design science
  • Design for assembly (DFA)
  • Taguchi method for robust design
  • Manufacturing planning and control
  • Computer Aided Process Planning (CAPP)
  • Computer-aided DFM (design for manufacturing)
  • Group technology (GT)
  • Failure-mode and effects analysis
  • Value engineering

35
Group Technology (GT)
An essential aspect of CAD/CAM integration is the
integration of information used in design and
manufacturing in all departments of an
organization. The group technology provides a
means to integrate this information about parts
that is easy to implement in computers and
analyze. There are several classification (or
coding) methods like hierarchical code, attribute
code, and hybrid code.
36
Manufacturing Planning and Control
Manufacturing planning and control activities
involve demand forecasts, master production
schedule (or aggregate planning), material
requirement planning (MRP), capacity planning,
shop-floor control, and quality control (QC). A
widely available commercial software is MAPICS
from IBM.
  • There are several approaches to achieve the
    efficient process planning such as
  • manual approach
  • variant approach
  • generative approach.

37
Computer Aided Process Planning (CAPP)
Process planning consists of a set of
instructions that describes how to manufacture a
part or build an assembly according to the given
manufacturing specifications. Since this is the
link between CAD and CAM, it is one of the key
elements in CAD/CAM integration and is drawing
more attentions of CAD/CAM developers in todays
competitive market. Computer-aided process
planning (CAPP) is now part of ongoing current
efforts in integration of CAD and CAM.
38
Cellular/Just-In-Time Manufacturing
As the competition in manufacturing market has
increased, many firms have realized the cellular
manufacturing and just-in-time (JIT)
manufacturing can provide significant advantages
such as reduced through-put, reduced
work-in-progress inventory, reduced materials
handling, and improved quality.
Cellular manufacturing is the organized
manufacturing activity such that a family of
parts or assembly can be efficiently fabricated
in a cell (i.e., a group of people and
manufacturing machines).
As it says JIT manufacturing is to deliver the
right number of parts to the right shop-floor
operation at the right time.
39
CAD/CAD System Integration
CAD systems are the starting point for production
of goods and there was considerable motivation to
provide a means for information derived from the
design process to migrate to the remainder of
manufacturing operation. This included
integration of CAD systems themselves,
integration with computer-aided manufacturing
systems, and integration with manufacturing
information systems.
CAD system integration involves the transfer of
designs among different systems. Integration with
CAM is probably more difficult than CAD-CAD
integration. Larger vendors normally offers CAM
packages as well, so it is possible to pass a
design data into machine tool control languages
like APT. There were also products which could
produce APT or other languages from IGES
(Initial Graphics Exchange Specification) designs.
IGES (Initial Graphics Exchange Standard) was
developed under the guidance of the National
Bureau of Standards in 1979 in order to provide a
tool for graphics data exchange in neutral
format. In addition, several other standards were
also proposed such as PDES (Product Data Exchange
Specification), EDIF (Electronic Design Interface
Format), GKS (Graphics Kernel System), and CORE.
The most widely supported is IGES and currently
many companies like Boeing Company, Sandia
National Laboratories, and General Motors use
IGES in production. Octal, Inc. provides an
interesting alternative to IGES which is the
direct conversion approach over neutral format
schemes and is recognized as the leader in CAD
database interchange. Octal provides many direct
converters among different CAD systems, for
example, Anvil 4000 to/from CADAM and CATIA
to/from Intergraph IGDS.
40
Part V CURRENT DEVELOPMENT
41
CAD
Graphics, Visualization, Geometric Modeling
  • Virtual reality
  • Computational geometry
  • Grammatical design and geometric representation
  • NURBS (Non-Uniform Rational B-Spline)

Modeling
  • Virtual reality
  • Computational geometry
  • Grammatical design and geometric representation
  • NURBS (Non-Uniform Rational B-Spline)

Rendering
User Interfaces
  • Virtual reality Modeling Language (VRML)

High Performance Architectures
42
Theory of Design
Feature-Based Design
Design Methodologies and Technologies
Integration of Distributed Computer-Controlled
Operations via Data Transfer in Network
Distributed Simulation via Network
Web-Based Electronic Design
Analog CAD
Hierarchical Sequential Interactive Synthesis
Layout-Driven Logic Synthesis
43
Hardware-Software Co-Simulation and Co-Design
Virtual Environments for Design
Virtual Environments for Ergonomic Design
Knowledge-Based Systems (or expert systems) with
Concurrent Engineering
Development of Means for Design Coordination or
Integrated Design CE
  • Field-Programmable Gate Arrays (FPGA) Synthesis
  • Multi-Chip Modules (MCM)
  • Integrated Circuit (IC) including VLIC
  • Near-Optimal Approximation Algorithms

Optimization
44
Management and Practice of Applications
Development
Digital Archive Development Based on Pattern
Recognition and Typified Protocols
Information Retrieval and Manipulation
Development of Part Library
Improvement of Product Information Management
Verification Interacting with Synthesis
Intelligent Design Support for Artificial
Intelligence and Advanced Computing Techniques
Case-Based Reasoning
Data Management Tools
45
CAE
Development of Computational Methods
Stereo Modeling
Application of Iterative Design Principles in
Development of Processes and Products
Scalable Computing for Large, Complex, and
Advanced Processing with Shared Computational
Resources
Mesh Generation in support of Numerical Methods
46
CAM
Machines and Machining Technologies
Nondeterministic Abstract Machines
Solid Manufacturing
Feature-Based Machining
High Strength Composite Manufacturing Techniques
Automated Milling, Welding, Coating, Painting,
etc.
Industrial Lasers
Mobile Robots
47
Computer-Aided Production Engineering (CAPE)
Process and Manufacturing Planning
Intelligent Product Manuals
Enterprise Information Management
Product Data Management
Automated Layout of Three-Dimensional Products
Optimization Development of Manufacturing
Software in Manufacturing
48
Sensing and Inspection
Machine Vision
Remote Sensing and Diagnostic Imaging
Automated Visual Inspection
Telerobotics
Product Quality Improvement
Nondestructive Testing Techniques
49
Virtual Reality (VR)
Virtual Manufacturing
Virtual Assembly
Virtual Environments for Telerobotics
Calibration in Virtual Environments
50
Integrated Manufacturing
  • Baseline Development Areas
  • Product representation through feature-based
    modeling
  • Knowledge-based applications supporting the
    entire life cycle
  • Engineering environment built around
    object-oriented, distributed computing systems
  • Direct manufacturing incorporating present
    practices and freeform fabrication

Integrated Product Development
Rapid Prototyping (RP)
Rapid Response Prototyping (RRP)
Rapid Response Testbed
  • Development and verification of advanced RRM
    application
  • Vendor product integration and interaction
    capability
  • Integrated use and management of core
    information models and application software
  • Concurrent information sharing
  • Part family specialization
  • Early validation of RRM requirements

Present framework
Present Applications
Reverse Engineering
51
Integrated Manufacturing (contd)
Rapid Prototyping (RP)
  • Reference architecture
  • Environment
  • Knowledge-based application

Present framework
Present Applications
  • Digital prototyping (or computational
    prototyping)
  • Computerized milling, forming, and spraying
  • Stereolithography

52
References
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Pennington Numerical Code Generation from
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Chang, T. C., R. A. Wysk, and R. P. Davis
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53
Conclusions
  • Design/Manufacturing/Verification
  • Time/Cost
  • Robot and Sensors in Product with AI
  • Data Exchangeability in All Steps
  • Integration over Network (LAN, InterNet)
  • Directions of Government Agencies

54
Directions of Government Agencies (Conclusions)
  • Focus on high-risk, high-payoff technologies with
    broad application
  • Address problems of sufficient size and scope to
    have a substantial effect
  • Achieve meaningful and measurable goals and
    ensure the development of technology that can be
    implemented and used
  • Build on the strengths of particular government
    agencies in assigning responsibilities
  • It clearly shows how the manufacturers should
    direct their efforts to stand ahead of others by
    prioritizing their focuses with effects in mind
    and achieving measurable goals in cooperation
    with closely related government agencies.

55
Already Identified Goals of Government Agencies
(Conclusions)
  • Agile manufacturing and flexible manufacturing
  • Rapid prototyping (virtual and physical) and
    direct fabrication
  • Intelligent controls and sensors
  • Especially advanced sensors, intelligent controls
    and innovative actuators are emphasized which
    will be vital elements in future manufacturing
    equipment and production systems.
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